Universität Stuttgart
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Item Open Access Wetting, de-icing and anti-icing behavior of microstructured and plasma-coated polyurethane films(2019) Grimmer, Philipp E. S.; Hirth, Thomas (Prof. Dr. rer. nat.)Ice build-up on surfaces, for example on wings of airplanes or on rotor blades of wind turbines, impairs the functionality of transportation vehicles or technical systems and reduces their safety. Therefore, functional anti-ice surfaces are being researched and developed, which shall enable an easy removal or reduce the amount of ice on the surfaces at risk. The starting hypothesis for this work is that superhydrophobic polyurethane (PU) films with microstructure base diameters of 35 µm or more reduce the wetting by water, show a low ice adhesion for easy removal of ice and reduce or delay icing. Superhydrophobic PU films for passive anti- and de-icing were created by hot embossing and plasma enhanced chemical vapor deposition (PECVD). The hot embossing process as well as the plasma coating and etching processes were analyzed for the dependence of the surface characteristics on different process parameters. The functionalized PU films were characterized for their surface topography, surface chemistry, stability against erosion, wettability, ice adhesion and icing behavior. For comparison, the ice adhesion and icing behavior were examined on relevant technical materials (aluminum, titanium, copper, glass, epoxy resin of carbon fiber reinforced polymer and other fluoropolymers) and on some commercial anti-ice coatings. The PU films were chemically analyzed by IR spectroscopy. As the first process step for functionalization, microstructures of cylindrical, elliptical or linear shape were imprinted in PU films by a hot embossing technique with different ns-pulsed laser-drilled stamps and characterized by several microscopy methods. The microstructures had heights of 15 µm to 140 µm, diameters or widths of 35 µm to 300 µm and distances (pitch values) of 50 µm to 500 µm. The embossing process was analyzed and optimized in terms of the process parameters temperature, pressure, time, PU film release temperature and reproducibility of the microstructures. In a second functionalization step (PECVD) the microstructured surfaces were coated with thin, hydrophobic plasma polymers using different fluorocarbon precursors (CHF3, C3F6 and C4F8) or hexamethyldisiloxane (HMDSO). Different process parameters for plasma coating and etching (Ar or O2 plasmas) were used in order to create various nanoscale roughness values. Electron spectroscopy for chemical analysis (ESCA), spectroscopic ellipsometry and atomic force microscopy (AFM) were used for analysis of the chemical composition, the thickness and the nanoroughness of the plasma polymers. The functionalizations, especially the plasma coatings, were completely worn off by a UV/water weathering test (1000 h, X1a CAM 180 Test, SAE J-2527), but showed sufficient stability against sand erosion (DIN 52348), in a long-term outdoor test for 13.5 months and against fivefold repeated pull-off of ice. The silicone-like plasma coatings were more stable than the fluorocarbon plasma coatings. The wetting behavior of water was determined by static, advancing and receding contact angle measurements. Static contact angle measurements with diiodomethane (DIM) were made for determination of the surface free energies of the relevant surfaces. Advancing contact angles of over 150° and very low contact angle hysteresis values below 10° were reached on some of the cylindrically and elliptically structured PU samples with microstructure base diameters in the range of 35 µm to 50 µm. The measured water advancing contact angles did not reach the theoretical values of the Cassie-Baxter state. Starting from a mixed wetting state near Cassie-Baxter in case of the superhydrophobic PU surfaces, they approached the Wenzel state with an increasing pitch/diameter (P/d) factor. Fluorescence laser scanning microscopy images were taken of some microstructured, uncoated or plasma coated samples during the wetting by a water drop containing a fluorescent dye. These images show the Wenzel state or a mixed wetting state by visualization of the interface between the water droplet and the surface. A new icing test chamber and a test setup were developed for characterization of the ice adhesion and the icing behavior. The tensile ice adhesion was measured at -20 °C by pull-off of ice cylinders (highly purified water, (<0.056 µS/cm, diameter of 4 mm, similar to the diameter of large raindrops) and compared to the theoretical values and the wetting behavior. The technical material surfaces measured for comparison showed a high ice adhesion, which led to cohesive fractures especially on the metal surfaces, whereas some of the commercial anti-ice coatings showed lower ice adhesion values. The flat, plasma coated PU surfaces showed adhesive fractures with a reduced ice adhesion compared to the technical material surfaces and uncoated PU and revealed a good correlation of the ice adhesion with the wetting behavior of water (work of adhesion). On the other hand, the microstructured PU surfaces showed a greatly increased ice adhesion in comparison to the flat PU and technical material surfaces which was enhanced even further by the plasma coatings and did not correlate with the wetting behavior. The reason for this is the wetting transition from the Cassie-Baxter to the Wenzel state during the cooling or freezing process, leading to an increased ice-surface contact area and mechanical interlocking of the ice with the micro- and nanostructures. The freezing of water drops was examined in thermodynamic equilibrium (static experiment) and under quasi-steady conditions (dynamic experiment). In the static experiment, 15 µl water drops (corresponding to medium to large raindrops) at room temperature were dispensed onto a cold surface at a constant temperature of -20 °C. The freezing delay times, the crystallization times and the total freezing times were measured and compared to calculated expected values. On the flat samples, the freezing delay times could be extended by the plasma treatments. On the microstructured samples, the freezing (nucleation) could sometimes be delayed even further, but not always reproducible because of an unstable Cassie-Baxter state. In the dynamic experiment, 25 µl water drops (corresponding to large raindrops) were cooled down in quasi-steady conditions with the surface and the surrounding atmosphere by a constant, low cooling rate of 1 K/min while the water drop temperature was measured by an IR camera for determination of the surface-specific nucleation temperature and crystallization time. A lower nucleation temperature could be measured on the flat, plasma coated PU surfaces compared to uncoated PU and the hydrophilic glass and metal surfaces. The superhydrophobic PU surfaces did not show a further reduction of the nucleation temperature because of an unstable Cassie-Baxter state. The resulting measured nucleation temperatures were compared to the expected values calculated with an enhanced nucleation theory including a quasi-liquid interfacial layer of the ice nucleus and a Poisson process. Overall, it is shown that hot embossing and PECVD are useful processes for creating superhydrophobic PU surfaces with regard to a roll-to-roll process. The flat, plasma coated PU films show a reduced ice adhesion and lowered nucleation temperature compared to the relevant technical material surfaces. The microstructured, plasma coated PU films are far more water repellent than the flat, plasma coated PU surfaces or the other technical materials. However, the microstructures with base diameters of 35 µm or more and the nanoroughness of the plasma coatings cannot stabilize the Cassie-Baxter state of a freezing water drop enough for a low ice adhesion or a significant decrease of the nucleation temperature. These superhydrophobic PU films are therefore not more icephobic than the flat, plasma coated PU films. In the outlook, the reduction of the geometrical parameters of the microstructures (diameter D, distance P) and nanostructures (curvature radius R) of the surface functionalizations for lower ice adhesion values and nucleation temperatures is proposed.Item Open Access Misfit-layered cobalt oxides for thermoelectric energy conversion(2017) Büttner, Gesine; Weidenkaff, Anke (Prof. Dr.)The conversion of waste heat into electrical current by a thermoelectric converter can significantly contribute to a more sustainable usage of our resources. The p-type misfit-layered [Ca2CoO3-δ][CoO2]1.62 is known for its promising conversion efficiency, which yet needs to be improved significantly for commercial applications. The efficiency of a material increases with the Figure of Merit ZT=σα^2/κ, with Seebeck coefficient α, electrical conductivity σ, and thermal conductivity κ. The aim of this thesis is to provide a better understanding of the electrical and the thermal properties of the complex [Ca2CoO3 δ][CoO2]1.62 and to use this understanding to improve the efficiency of converters. Accordingly, (i) the increase of ZT via cation substitution is shown; (ii) a better understanding of the electrical transport above room temperature is developed; (iii) the effect of stoichiometric defects and secondary phases on the thermoelectric properties is investigated. Finally, (iv) [Ca2CoO3 δ][CoO2]1.62 - CaMn0.97W0.03O3 δ - converters are fabricated and the efficiency is increased by a suitable converter design. More specifically, the unexplored influence of Ru and In substitution on the thermoelectric properties of the polycrystalline [Ca2CoO3 δ][CoO2]1.62 is investigated. While In does not have a positive effect, Ru for Co substitution increases ZT up to 20 %. This increase stems from a strong reduction of the thermal conductivity - which is probably induced by resonance scattering - while the decrease of the power factor α^2 σ is minor. The electrical transport mechanism of pure and Ru-substituted [Ca2CoO3 δ][CoO2]1.62 between room temperature and 800 K so far lacks a coherent theoretical model. Surprisingly, the framework of Anderson localization, which was developed to describe conduction in an impurity band of semiconductors, can be applied to the oxide. The Anderson model assumes that transport happens via charge-carrier hopping in a random Coulomb potential. For [Ca2CoO3 δ][CoO2]1.62, charges are considered to hop between Co sites in the CoO2 layer, while the random potential originates from interactions with the mismatched Ca2CoO3 δ layer. The presence of the ionized Ru atoms further alters the Coulomb potential, which increases the activation energy of the transport behavior. This understanding might contribute to the development of better theoretical models for the prediction of the thermoelectric properties of substituted [Ca2CoO3 δ][CoO2]1.62 compounds. A further improvement of the materials efficiency can be achieved by systematic introduction of stoichiometric defects and impurity phases. Here, the unexplored influence of the Co/Ca ratio on the thermoelectric properties of [Ca2 wCoO3 δ][CoO2]1.62, and the effect of Co3O4 impurity phase are investigated. It is shown that an increasing Co/Ca ratio in the [Ca2 wCoO3 δ][CoO2]1.62 phase leads to a larger figure of merit ZT induced by a strong resistivity drop. The decrease of resistivity stems from additional p-type charge carriers created by the formation of Ca vacancies. The Co3O4 impurity phase increases the thermal conductivity of the composite samples and leads to a reduction of ZT when the volume fraction of the Co3O4 phase is increased from 1% to 3%. Hence, the best figure of merit is expected close to the upper phase boundary of the [Ca2 wCoO3 δ][CoO2]1.62 phase. Not only the figures of merit of the materials, but also the design of a thermoelectric converter determines the device efficiency. In a converter, a p-type and a suitable n-type thermoelectric material are connected electrically in series and thermally in parallel. Here, [Ca2 wCoO3 δ][CoO2]1.62 is combined with the n-type CaMn0.97W0.03O3-δ and the device efficiency is improved by a variation of the ratio A_p/A_n of the cross section areas of the legs. The good agreement between the experimental values and the predictions of the compatibility model show the high quality of the fabricated devices and the value of the model for the optimization of the converter design. The adjustment of A_p/A_n improves the power output and the efficiency of the converters, where the best volume and area power densities exceed published high temperature values. The achieved efficiency of 1.08 % at a temperature of 1085 K at the hot side is close to the theoretical expected efficiency and can be further improved via ZT.